Elastomer seal spring

ABSTRACT

The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within a conductive female housing and connector assembly. The seal spring compresses and provides adequate spring force against a disk ferrule assembly, pressing the disk ferrule assembly, with a wire shield, against a conductive female outer housing, providing a grounding scheme for the connector assembly. The seal spring also seals against the female outer housing and a wire.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims priority to 63/169,511 Apr. 1, 2021 andU.S. Provisional Patent Application No. 63/051,517 filed Jul. 14, 2020,which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

Silicone or any elastomer material (material that is rubber like innature) is often used in applications, specifically in electricalconnector systems, as a material which will form a seal for the purposeof preventing outside elements, such as but not limited to, water, air(any gaseous element or molecule), or any debris defined as any foreignmaterial not present when the connector system is assembled, fromentering into the connector system. The sealing property of a specificseal is accomplished by the elastomeric property of the material and theproper geometric shape or shapes for operating within its location inthe connector system. These seals are often named based on theirintended location of use, with terms such as face seal, interface seal,ring seal, cable seal, mat (or matte) seal, and wire seal.

Description of the Related Art EXAMPLE 1

The use of a silicone (elastomer) seal in a connector application mayinclude a mat (or matte) seal. The mat (matte) seal may be used in aheader or device configuration connector assembly where it functions ina singular function as a seal. The mat (matte) seal are performing asingular function (sealing), sealing against two independent (separate)surfaces. And a back cover typical of designs using a mat (matte) seal,will secure and protect the mat (matte) seal.

EXAMPLE 2

The use of a silicone (elastomer) seal in a connector application mayinclude two mat (matte) seals. The two mat (matte) seals may be usedwithin a wire to wire (inline) configuration connector assembly. One mat(matte) seal being a female mat (matte) seal, the other is a male mat(matte) seal. Both of the mat (matte) seals are sealing, for example, alocation between the seal and a plastic housing, as well as, sealingbetween the seal and wires that travel through an inner cavity of themat seal. Note, the mat (matte) seals are performing a singular function(sealing) but are sealing against two independent (separate) surfaces,respectively. And a back cover is included for each seal which istypical of designs using a mat (matte) seal, to secure and protect themat (matte) seal.

EXAMPLE 3

The use of a silicone (elastomer) seal in a connector application mayinclude an overmolded mat seal and a face seal. The overmolded mat sealand the face seal may , be used within a cast device with face sealconfiguration connector assembly. The overmolded mat (matte) seal issealing, for example, a location between the seal and a plastic housing,as well as, sealing between the seal and a wire that travels through theinner cavity of the overmolded mat (matte) seal. The face seal is onecontinuous seal which is sealing between the plastic housing and thecast device. The seal is operating not unlike a gasket or O-ring.

Note, the mat (matte) seal and the face seal are performing a singularfunction (sealing) wherein, the mat (matte) seal is sealing against twoindependent (separate) surfaces, respectively and the overmolded mat(matte) seal is sealing against a single surface. And a back cover isincluded, which is again typical of designs using a mat (matte) seal, tosecure and protect the mat (matte) seal.

SUMMARY OF THE INVENTION

The seal spring of the present invention has a dual functionality. Inuse, the seal spring provides both a sealing property and springfunction within an electrical connector assembly. The dual functionalityis accomplished by its elastomeric qualities. The seal spring iscomprised of Silicone, EPDM rubber, materials and compositions whichprovide similar performance during use, or the like. Additionally, theseal spring of the present invention is also not limited or defined intoa spring section or a seal section by its geometry. Thus, the sealspring is not geometry based and it may function anywhere the dualfunctionality of a seal function and spring function is required. Onesuch implementation is within an inner cavity of a housing of aconnector assembly, which is described in detail in the presentapplication.

A connector assembly having the seal spring of the present inventionwill also preferably contain a disk ferrule assembly. The seal springwill interact with the disk ferrule assembly. In use, the seal springwill be compressed and deformed, pressing against the disk ferruleassembly on one end and a housing back cover on the other end. The sealspring will therefore provide a spring function. Additionally, the diskferrule assembly provides a grounding device for the connector assemblyvia a wire shield attached to the disk ferrule assembly. For the diskferrule assembly to assist with the grounding of the connector assembly,it is required for the disk ferrule assembly to, for example, contact agrounding scheme, In the present application the grounding schemeincludes a conductive housing (made of metallic infused resin) but mayalso be a conductive element (ie. traditional stamped shield or similargrounding device) within the housing, but the grounding device is notlimited thereto these aforementioned examples.

Here, in use, the seal spring of the present invention is beingcompressed and deformed into an inner cavity of a female outer housing.The seal spring is compressed into the inner cavity when a housing backcover is mated and secured with the female outer housing. Theelastomeric properties and durometer specification of the seal springallows the compressed state of the seal spring to exert a spring forceagainst both the housing back cover and, more importantly, the diskferrule assembly. The seal spring generates and exerts an outward springforce which acts to push the seal spring against the disk ferruleassembly, securing the disk ferrule assembly to an inner wall of thefemale outer housing (conductive housing) or to a grounding device (ie.traditional stamped shield) within the female outer housing (not shown).

Additionally, the sealing properties of the seal spring allow thecompressed seal spring to maintain and provide an outer sealing functionagainst the female outer housing 210 and inner sealing function againstthe wire 300.

The seal spring, as is shown, may also have a protrusion assisting inthe contact of the seal spring with the disk ferrule assembly and/orhousing back cover without disturbing the deformation or sealinggeometry of the seal spring in use and operation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front perspective view of the seal spring of the presentinvention.

FIG. 2 is a rear perspective view of the seal spring of the presentinvention.

FIG. 3 is an end perspective view of the housing back cover of thepresent invention.

FIG. 4 is a cross section view of the female housing with a wireinserted with a disk ferrule assembly installed.

FIG. 5 is a cross section view of the female housing with a wireinserted, the disk ferrule assembly installed, and the seal springresiding in the female housing.

FIG. 6 is a cross section view of the assembled housing assembly havingthe female housing with a wire inserted, the disk ferrule assemblyinstalled, the seal spring residing in the female housing, and with thehousing back cover installed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As seen in FIG. 1 is the preferred embodiment of the seal spring 100 ofthe present invention. The seal spring 100 is preferably comprised ofsilicone, EPDM rubber or materials and compositions that provide similarperformance during use, or the like. The seal spring 100 has a firstface 102, a first face surface 112, a second face 104, a second facesurface 114 and a side 106. The side 106 having a surface 116 and theside 106 being between the first face 102 and second face 104. The sealspring 100 also has an outer sealing portion 120 which is on a portionof the side 106 and is formed by a portion of the side surface 116.Here, the outer sealing portion 120 is preferably substantiallycentrally located on the side 106 (See FIG. 1, 2 ), Further, the sealspring 100 has an inner aperture 108, having a side wall 109. The sidewall 109 having a surface 110. A quantity of two inner aperture 108 areshown in FIGS. 1 and 2 , the quantity of inner aperture 108 ispreferably one or greater than one. Additionally, the seal spring 100has an inner sealing portion 130 located inside the inner aperture 108on a portion of its respective side wall 109 and formed by a portion ofthe side surface 110. Here, the inner sealing portion 130 is preferablysubstantially centrally located on the side wall 109.

The seal spring 100, as shown, also has a protrusion 140 which surroundsand corresponds with the inner aperture 108. As shown in FIG. 1 and FIG.2 , the protrusion 140 protrudes from both the first face 102 and thesecond face 104 respectively. Alternatively, another embodiment may havethe protrusion 140 protruding from either the first face 102 or thesecond face 104 (not shown). The protrusion 140 has a side surface 144and a vertical surface 142. The side surface 144 is substantiallyperpendicular to the respective first face 102, or second face 104, fromwhich it extends. The vertical surface 142 is substantially parallel tothe respective first face 102, or second face 104, from which itextends. Additionally, the side surface 144 and the vertical surface 142meet at and extend substantially perpendicular to one another.

The seal spring 100, as shown, has two of the inner aperture 108, with acorresponding pair of protrusions 140, one extending from the first face102 and one extending from the second face 104 (see, FIGS. 1-2, 5-6 ).As previously mentioned, the quantity of inner aperture 108 ispreferably one or greater than one and is not limited hereto. Likewise,the quantity of protrusion 140 corresponding to a quantity of inneraperture 108 is preferably one or two, and more preferably the quantityof the protrusion 140 is two per quantity of inner aperture 108, a pair,wherein one of the two protrusions 140 extends from the first face 102and the other one of the two protrusions 140 extends from the secondface 104 (see, FIGS. 1-2, 5-6 ).

FIG. 2 illustrates the second face 104 and second face surface 114 ofseal spring 100. The side 106 having a side surface 116 is alsoillustrated. As previously mentioned, the seal spring 100 has an outersealing portion 120 and an inner sealing portion 130. The outer sealingportion 120 interacts and seals with a female outer housing 210 ofconnector assembly 200 as (see, FIG. 6 ). The inner sealing portion 130interacts and seals with an inner insulation 302 of a wire 300 as willbe discussed in more detail later (see, FIG. 6 ).

Shown in FIG. 3 is the housing back cover 230 of the connector assembly200. The housing back cover 230 has an inner cavity 231. The innercavity 231 has a side wall 233. The side wall 233 has a surface 234.Additionally, the inner cavity 231 of the housing back cover 230 has anopening 232 within a first end portion 237 and surface of the first endportion 238. Further, the housing back cover 230 has a second endportion 239. The end portion 239 has an outer surface 240. The innercavity 231 additionally has a rear wall 235, the rear wall 235 is partof the second end portion 239. The rear wall 235 has an inner surface236. Additionally, extending substantially perpendicular from the secondend portion 239 is a wire collar strain relief 245 of the housing backcover 230. The housing back cover 230 has an aperture 241 extendingthrough the rear wall 235 of the second end portion 239. The aperture241 further extends and is within the wire collar strain relief 245. Theaperture 241 has a side wall 242. The side wall 242 has a surface 243.The aperture 241 corresponds and centrally aligns to each of an inneraperture 108 provided in the seal spring 100 respectively.

In FIG. 4 is an illustration of the female outer housing 210 containingthe wire 300. The female outer housing 210 has an inner cavity 211. Theinner cavity 211 has a side wall 213. The side wall 213 has a surface214. Additionally, the inner cavity 211 of the female outer housing 210has an opening 212 at an end portion 217. The end portion 217 has asurface 218. The inner cavity 211 additionally has a rear wall 215. Therear wall 215 has a surface 216.

Also detailed in FIG. 4 is the wire 300. The wire 300 has a wire core301, an inner insulation 302, a wire outer insulation 304 and a wireshield 500. The wire 300 has an axial direction A (as labeled in FIG. 6). The wire shield 500 is located between the inner insulation 302 andthe outer insulation 304 of the wire 300. The wire core 301 is locatedwithin the inner insulation 302.

Further, in FIG. 4 , the wire 300 is inserted into the female outerhousing 210. One end of the wire core 301 is fixed and connected to aterminal (not shown). The terminal is locked within the female outerhousing 201. Therefore the wire core 301 is secured and fixed frommoving once the terminal is locked within the female outer housing 201,and the wire 300 is thus also locked in place, and its forward motion isinhibited and limited.

Also seen in FIG. 4 is the disk ferrule assembly 400 which is positionedover the inner insulation 302 of the wire 300 and inside the innercavity 211 of the female outer housing 210. In FIG. 4 , a portion of theouter insulation 304 has been removed whereby the disk ferrule assembly400 is located adjacent to a free end portion of the outer insulation304. The wire shield 500 will be either within the disk ferrule assembly400 or located on one side or the other, and fixed or secured to thedisk ferrule assembly 400. Thus the portion of the wire shield 500 incontact or secured with the disk ferrule assembly 400 will accordinglymove with, and be positioned with, the disk ferrule assembly 400.

As shown in FIG. 5 , the seal spring 100 is inserted into the femaleouter housing 301. The inner insulation 302 of the wire 300 is insertedand extends through the inner aperture 108 of the seal spring 100. Theseal spring 100 is then inserted into the opening 212 of the innercavity 211 of the female outer housing 210 while the seal spring 100 ismoved along the axial direction A of the wire 300 and is furtherinserted towards and contacts the disk ferrule assembly 400. The sealspring 100 is limited by its movement further into the female outerhousing 210 when the first face surface 112 of the first face 102reaches and abuts the disk ferrule assembly 400. As seen in FIG. 5 , thesecond face 104 and second face surface 114 of seal spring 100 protrudesfrom and extends outside of the inner cavity 211 of the female outerhousing and within and past the opening 212 of the female outer housing210.

As shown in FIG. 6 , the housing back cover 230 may interact with and besecured onto the female outer housing 210. The housing back cover 230has retention tabs 244 for interacting with protrusions (not shown) onthe exterior of the female outer housing 210. The retention tabs 244allow the housing back cover 230 to be aligned, positioned, locked andsecured to the exterior of the female outer housing 210. A portion ofthe female outer housing 210 will reside fully within the inner cavity231 of the housing back cover 230. The female outer housing 210 willcontact the surface 234 of the side wall 233 of the inner cavity 231 ofthe housing back cover 230. During mating, the female outer housing 210will enter and pass through the opening 232 of the housing back cover230. When the female outer housing 210 is fully mated and inserted intothe inner cavity 231 of the housing hack cover, the end portion 217 andend portion surface 218 of the female outer housing 210 contacts andabuts the rear wall 235 of the inner cavity 231 of the housing backcover 230, on the inner surface 236 of the rear wall 235 of the innercavity 231 of the housing back cover 230. This will limit the forwardmotion of the female outer housing 210 into the housing back cover 230,and preferably locates the female outer housing 210 within the housingback cover 230 for operation and use of the connector assembly 200.

Further, the housing back cover 230 also interacts with the seal spring100. During the mating of the housing back cover 230 and female outerhousing 210, the housing back cover 230 pushes against and abuts againstthe protrusion 140 of the seal spring 100. The protrusion 140 isprotruding from the second face 104 of the seal spring. The inner wallof the housing back cover 230 abuts the vertical surface 142 ofprotrusion 140 extending from the second face 104 of the seal spring100. Likewise, the vertical surface 142 of protrusion 140 extending fromthe first face 102 of the seal spring 100 is in full contact with thedisk ferrule assembly 400. As the housing back cover 230 and the femaleouter housing 210 mate, the seal spring 100 is compressed in the axialdirection A of the wire 300. Once the housing back cover 230 is securedand locked to the female outer housing 210 with retention tabs 244locking to the exterior of the female outer housing 210, the seal spring100 is fully compressed and fully resides within the inner cavity 211 ofthe female outer housing 210.

As in FIG. 6 , the fully compressed and deformed, orientation or stateof the seal spring 100, provides a spring-like force and spring functionin two opposite directions along the axial direction A of the wire 300.First, towards the disk ferrule assembly 400 and second, towards thehousing back cover 230. The spring-like force exerted towards the diskferrule assembly 400 by the seal spring 100 provides a securing forcefor the disk ferrule assembly 400 which keeps or retains the diskferrule assembly 400 in a state and position where the disk ferruleassembly 400 is abutting and fully contacting against the rear wall 215of the inner cavity 211 of the female outer housing 210 (conductive), orto a stamped shield (not shown), or a similar grounding device withinthe inner cavity 211 of the female outer housing 210. The female outerhousing 210 here has metallic properties (metal infused resin ormetallic composition) wherein the female outer housing 210 is aconductive element which completes a grounding path or scheme for theconnector assembly 200 by grounding the wire shield 500 provided to thedisk ferrule assembly 400.

Additionally, in FIG. 6 , while providing adequate spring force, thecompressed seal spring 100 will maintain and provide an outer sealingfunction against the female outer housing 210 and inner sealing functionagainst the wire 300. The outer sealing portion 120 of the seal spring100 will seal against the surface 214 of the side wall 213 of the innercavity 211 of the female outer housing 210 (see, FIG. 6 ). The innersealing portion 130 of the seal spring 100 will seal against the innerinsulation 302 of the wire 300 (see, FIG. 6 ). Thus, the seal spring 100is sealing against two independent, separate surfaces.

The elastic properties and durability of the seal spring 100 material isoptimized such that the aforementioned combination of properties andeffects is provided. Additionally, the seal spring 100 of the presentinvention is not limited or defined into a spring section or a sealsection by its geometry. Thus, the seal spring 100 is not geometry basedand it may function anywhere the dual functionality of a seal functionand spring function is required. Further, the size or space of the innercavity 211 of the female outer housing 210, may be optimized andadjusted to allow for deformation of the seal spring 100 in order tomigrate and not interrupt the spring function or the inner and outersealing properties of the seal spring 100. Alternatively, the size ofthe protrusion 140 of the seal spring 100 may be optimized and adjustedto allow for deformation of the seal spring 100 in order to migrate andnot interrupt the spring function or the inner and outer sealingproperties of the seal spring 100.

Although the foregoing descriptions are directed to preferredembodiments in the manufacturing method for assembling at least thevertical disk ferrule of this invention, it is noted that othervariations and modifications will be apparent to those skilled in theart, and may be made without departing from the spirit or scope of theinvention. Moreover, the manufacturing method for assembling at leastthe vertical disk ferrule of this invention in connection with oneembodiment of the invention may be used in conjunction with otherembodiments, even if not explicitly state above.

I Claim:
 1. A method for assembling a seal spring in a connectorassembly, comprising the steps of: inserting said seal spring over awire; inserting said seal spring into an inner cavity of a housing;pushing said housing into a housing back cover; thereafter, pushing saidhousing into said housing back cover so as to provide a lock positionfor a retention tab on a protrusion located on said housing; compressingseal spring within said housing; pressing seal spring against a diskferrule assembly; and thereafter, providing a spring force to said sealspring, wherein the wire is accommodated by an inner aperture of saidseal spring, and a face of said seal spring has a protrusion surroundingand corresponding with said inner aperture, and wherein said protrusionof said seal spring extends from said face of said seal spring and is incontact with said housing back cover, wherein a second face of said sealspring has a second protrusion extending from said second face of saidseal spring, said second face of said seal spring being opposite to saidface of said seal spring.
 2. The method according to claim 1, whereinsaid step of pressing seal spring against said disk ferrule assembly,presses said disk ferrule assembly against said housing after said stepof providing a spring force to said seal spring.
 3. The method accordingto claim 1, wherein said method for assembling a seal spring in saidconnector assembly, said seal spring presses against said housing backcover after said step of providing a spring force to said seal spring.4. The method according to claim 1, wherein said method for assembling aseal spring in said connector assembly, includes providing said housingwith a grounding device.
 5. A method according to claim 1, wherein saidseal spring seals against said inner cavity of said housing.
 6. A methodaccording to claim 1, wherein said seal spring seals against said wire.7. A method according to claim 1, wherein a second face of said sealspring has said second protrusion surrounding and corresponding withsaid inner aperture, said second protrusion of said seal spring being incontact with said disk ferrule assembly.